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This study aims to comprehensively investigate the mixed-mode fracture behavior and mechanical properties of selective laser sintering (SLS) polyamide 12 (PA12) components, considering different build orientations and layer thicknesses. The primary objectives include the following. Conducting mixed-mode fracture and mechanical analyses on SLS PA12 parts. Investigating the influence of build orientation and layer thickness on the mechanical properties of SLS-printed components. Examining the fracture mechanisms of SLS-produced Arcan fracture and tensile specimens through experimental methods and finite element analyses.

The research used a combination of experimental techniques and numerical analyses. Tensile and Arcan fracture specimens were fabricated using the SLS process with varying build orientations (X, X–Y, Z) and layer thicknesses (0.1 mm, 0.2 mm). Mechanical properties, including tensile strength, modulus of elasticity and critical stress intensity factor, were quantified through experimental testing. Mixed-mode fracture tests were conducted using a specialized fixture, and finite element analyses using the J-integral method were performed to calculate fracture toughness. Scanning electron microscopy (SEM) was used for detailed morphological analysis of fractured surfaces.

The investigation revealed that the highest tensile properties were achieved in samples fabricated horizontally in the X orientation with a layer thickness of 0.1 mm. Additionally, parts manufactured with a layer thickness of 0.2 mm exhibited favorable mixed-mode fracture behavior. The results emphasize the significance of build orientation and layer thickness in influencing mechanical properties and fracture behavior. SEM analysis provided valuable insights into the failure mechanisms of SLS-produced PA12 components.

This study contributes to the field of additive manufacturing by providing a comprehensive analysis of the mixed-mode fracture behavior and mechanical properties of SLS-produced PA12 components. The investigation offers novel insights into the influence of build orientation and layer thickness on the performance of such components. The combination of experimental testing, numerical analyses and SEM morphological observations enhances the understanding of fracture behavior in additive manufacturing processes. The findings contribute to optimizing the design and manufacturing of high-quality PA12 components using SLS technology.

This study aims to investigate the thermal fracture mechanism of moisture-preconditioned SAC305 ball grid array (BGA) solder joints subjected to multiple reflow and thermal cycling.

The BGA package samples are subjected to JEDEC Level 1 accelerated moisture treatment (85 °C/85%RH/168 h) with five times reflow at 270 °C. This is followed by multiple thermal cycling from 0 °C to 100 °C for 40 min per cycle, per IPC-7351B standards. For fracture investigation, the cross-sections of the samples are examined and analysed using the dye-and-pry technique and backscattered scanning electron microscopy. The packages' microstructures are characterized using an energy-dispersive X-ray spectroscopy approach. Also, the package assembly is investigated using the Darveaux numerical simulation method.

The study found that critical strain density is exhibited at the component pad/solder interface of the solder joint located at the most distant point from the axes of symmetry of the package assembly. The fracture mechanism is a crack fracture formed at the solder's exterior edges and grows across the joint's transverse section. It was established that Au content in the formed intermetallic compound greatly impacts fracture growth in the solder joint interface, with a composition above 5 Wt.% Au regarded as an unsafe level for reliability. The elongation of the crack is aided by the brittle nature of the Au-Sn interface through which the crack propagates. It is inferred that refining the solder matrix elemental compound can strengthen and improve the reliability of solder joints.

Inspection lead time and additional manufacturing expenses spent on investigating reliability issues in BGA solder joints can be reduced using the study's findings on understanding the solder joint fracture mechanism.

Limited studies exist on the thermal fracture mechanism of moisture-preconditioned BGA solder joints exposed to both multiple reflow and thermal cycling. This study applied both numerical and experimental techniques to examine the reliability issue.

This paper aims to provide SIF calculation method for engineering application.

In this paper, the stress intensity factors (SIFs) calculation method is applied to the anisotropic Ni-based single crystal film cooling holes (FCHs) structure.

Based on contour integral, the anisotropic SIFs analysis finite element method (FEM) in Ni-based single crystal is proposed. The applicability and mesh independence of the method is assessed by comparing the calculated SIFs using mode of plate with an edge crack. Anisotropic SIFs can be calculated with excellent accuracy using the finite element contour integral approach. Then, the effect of crystal orientation and FCHs interference on the anisotropic SIFs is clarified. The SIFs of FCH edge crack in the [011] orientated Ni-based single crystal increases faster than the other two orientations. And the SIF of horizontal interference FCHs edge crack is also larger than that of the inclined interference one.

The SIFs of the FCH edge crack in the turbine air-cooled blade are innovatively computed using the sub-model method. Both the Mode I and II SIFs of FCHs edge crack in blade increase with crack growing.

This research outlines the development and characterization of advanced composite materials and their potential applications in the aerospace industry for interior applications. Advanced composites, such as carbon-fiber-reinforced polymers and ceramic matrix composites, offer significant advantages over traditional metallic materials in terms of weight reduction, stiffness and strength. These materials have been used in various aerospace applications, including aircraft, engines and thermal protection systems.

The development of design of experiment–based hybrid aluminum composites using the stir-casting technique has further enhanced the performance and cost-effectiveness of these materials. The design of the experiment was followed to fabricate hybrid composites with nano cerium oxide (nCeO₂) and graphene nanoplatelets (GNPs) as reinforcements in the Al-6061 matrix.

The Al6061 + 3% nCeO2 + 3% GNPs exhibited a high hardness of 119.6 VHN. The ultimate tensile strength and yield strength are 113.666 MPa and 73.08 MPa, respectively. A uniform distribution of reinforcement particulates was achieved with 3 Wt.% of each reinforcement in the matrix material, which is analyzed using scanning electron microscopy. Fractography revealed that brittle and ductile fractures caused the failure of the fractured specimens in the tensile test.

The manufactured aluminum composite can be applied in a range of exterior and interior structural parts like wings, wing boxes, motors, gears, engines, antennas, floor beams, etc. The fan case material of the GEnx engine (currently using carbon-fiber reinforcement plastic) for the Boeing 7E7 can be another replacement with manufactured hybrid aluminum composite, which predicts weight savings per engine of close to 120 kg.

The development of hybrid reinforcements, where two or more types of reinforcements are used in combination, is also a novel approach to improving the properties of these composites. Advanced composite materials are known for their high strength-to-weight ratio. If the newly developed composite material demonstrates superior properties, it can potentially be used to replace traditional materials in aircraft manufacturing. By reducing the weight of aircraft structures, fuel efficiency can be improved, leading to reduced operating costs and environmental impact. This allows for a more customized solution for specific application requirements and can lead to further advancements in materials science and technology.

The purpose of this paper is to determine the ultra-high cycle fatigue behavior and ultra-slow crack propagation behavior of selective laser melting (SLM) AlSi7Mg alloy under as-built conditions.

Constant amplitude and two-step variable amplitude fatigue tests were carried out using ultrasonic fatigue equipment. The fracture surface of the failure specimen was quantitatively analyzed by scanning electron microscope (SEM).

The results show that the competition of surface and interior crack initiation modes leads to a duplex S–N curve. Both manufacturing defects (such as the lack of fusion) and inclusions can act as initially fatal fatigue microcracks, and the fatigue sensitivity level decreases with the location, size and type of the maximum defects.

The research results play a certain role in understanding the ultra-high cycle fatigue behavior of additive manufacturing aluminum alloys. It can provide reference for improving the process parameters of SLM technology.

This study aims to investigate the performance of filament-based material extrusion additive manufacturing (MEX), combined with debinding and sintering, as a novel approach to manufacturing ceramic components.

A commercial ZrO₂ filament was selected and analysed by infra-red (IR) spectroscopy, rheology and thermo-gravimetry. The influence of the print parameters (layer thickness, flow rate multiplier, printing speed) and sintering cycle were investigated to define a suitable printing and sintering strategy. Biaxial flexure tests were applied on sintered discs realised with optimised printing strategies, and the results were analysed via Weibull statistics to evaluate the mechanical properties of printed components. The hardness and thermal conductivity of sintered components were also tested.

Layer thickness and flow rate multiplier of the printing process were proved to have significant effect on the density of as-printed parts. Optimised samples display a sintered density >99% of the theoretical density, 20% linear sintering shrinkage, a characteristic flexural strength of 871 MPa with a Weibull modulus of 4.9, a Vickers hardness of 12.90 ± 0.3 GPa and a thermal conductivity of 3.62 W/mK. Gyroids were printed for demonstration purposes.

To the best of the authors’ knowledge, this work is the first to apply biaxial flexure tests and Weibull statistics to additively manufactured MEX zirconia components, hence providing comparable results to other additive technologies. Moreover, fractography analysis builds the connection between printing defects and the fracture mechanism of bending. This study also provides guidelines for fabricating high-density zirconia components with MEX.

This paper aims to employ a multivariate nonlinear regression analysis to establish a predictive model for the final fracture area, while accounting for the impact of individual parameters.

This analysis is based on the numerical simulation data obtained, using the hybrid finite element–discrete element (FE–DE) method. The forecasting model was compared with the numerical results and the accuracy of the model was evaluated by the root mean square (RMS) and the RMS error, the mean absolute error and the mean absolute percentage error.

The multivariate nonlinear regression model can accurately predict the nonlinear relationships between injection rate, leakoff coefficient, elastic modulus, permeability, Poisson’s ratio, pore pressure and final fracture area. The regression equations obtained from the Newton iteration of the least squares method are strong in terms of the fit to the six sensitive parameters, and the model follow essentially the same trend with the numerical simulation data, with no systematic divergence detected. Least absolutely deviation has a significantly weaker performance than the least squares method. The percentage contribution of sensitive parameters to the final fracture area is available from the simulation results and forecast model. Injection rate, leakoff coefficient, permeability, elastic modulus, pore pressure and Poisson’s ratio contribute 43.4%, −19.4%, 24.8%, −19.2%, −21.3% and 10.1% to the final fracture area, respectively, as they increased gradually. In summary, (1) the fluid injection rate has the greatest influence on the final fracture area. (2)The multivariate nonlinear regression equation was optimally obtained after 59 iterations of the least squares-based Newton method and 27 derivative evaluations, with a decidability coefficient R2 = 0.711 representing the model reliability and the regression equations fit the four parameters of leakoff coefficient, permeability, elastic modulus and pore pressure very satisfactorily. The models follow essentially the identical trend with the numerical simulation data and there is no systematic divergence. The least absolute deviation has a significantly weaker fit than the least squares method. (3)The nonlinear forecasting model of physical parameters of hydraulic fracturing established in this paper can be applied as a standard for optimizing the fracturing strategy and predicting the fracturing efficiency in situ field and numerical simulation. Its effectiveness can be trained and optimized by experimental and simulation data, and taking into account more basic data and establishing regression equations, containing more fracturing parameters will be the further research interests.

The nonlinear forecasting model of physical parameters of hydraulic fracturing established in this paper can be applied as a standard for optimizing the fracturing strategy and predicting the fracturing efficiency in situ field and numerical simulation. Its effectiveness can be trained and optimized by experimental and simulation data, and taking into account more basic data and establishing regression equations, containing more fracturing parameters will be the further research interests.

Multi-well hydrofracturing is an important technology to create new fractures and expand existing fractures to increase reservoir permeability. The propagation morphology of the fracture network is affected by the disturbance between the fractures initiation sequences and spacings between adjacent wells. However, it remains unclear how well spacing and initiation sequences lead to fracture propagation, deflection and connection.

In this study, the thermal-hydro-mechanical coupling effect in the hydrofracturing process was considered, to establish a finite element-discrete element model of multistage hydrofracturing in a horizontal well. Using typical cases, the unstable propagation of hydraulic fractures in multiple horizontal wells was investigated under varying well spacing and initiation sequences. Combined with the shear stress shadow caused by in situ stress disturbed by fracture tip propagation, the quantitative indexes of fracture propagation such as length, volume, displacement vector, deflection and unstable propagation behavior of the hydrofracturing fracture network were analyzed.

The results show that the shear stress disturbance caused by multiple hydraulic fractures is a significant factor in multi-well hydrofracturing. Reducing the spacing between multiple wells increases the stress shadow area and aggravates the mutual disturbance and deflection between the fractures. The quantitative analysis results show that a decrease of well spacing reduces the total length of hydraulic fractures but increases the total volume of the fracture; compared with sequential and simultaneous fracturing, alternate fracturing can effectively reduce stress shadow area, alleviate fracture disturbance and generate larger fracture propagation length and volume.

The numerical models and results of the unstable propagation and stress evolution of the hydraulic fracture network under thermal-hydro-mechanical coupling obtained in this study can provide useful guidance for the evaluation and design of rock mass fracture networks in deep unconventional oil and gas reservoirs.

Thermal fractures initiated under cooling at the surfaces of a 2-D or 3-D structure propagate, arrest and coalesce, leading to its structural failure and material-property changes, while the same processes can happen in the rock mass between parallel hydraulic fractures filled with cold fluid, leading to enhanced fracture connectivity and permeability.

This study used a 2-D plane strain fracture model for mixed-mode thermal fractures from two parallel cooling surfaces. Fracture propagation was governed by the theory of linear elastic fracture mechanics, while the displacement and temperature fields were discretized using the adaptive finite element method. This model was validated using two numerical benchmarks with strong fracture curvature and then used to simulate the propagation and coalescence of thermal fractures in a long rock mass.

Modeling results show two regimes: (1) thermal fractures from a cooling surface propagate and arrest by following the theoretical solutions of half-plane fractures before the unfractured portion decreases to 20% rock-mass width and (2) some pairs of fractures from the opposite cooling surfaces tend to eventually coalesce. The fracture coalescence time is in a power law with rock-mass width.

These findings are relevant to both subsurface engineering and material engineering: structure failure is a key concern in the latter, while fracture coalescence can enhance the connectivity of thermal and hydraulic fractures and thus reservoir permeability in the former.

1) The OE-MLPG penalty meshfree method is developed to solve cracked structure.(2) Smartening the numerical meshfree method by combining the particle swarm optimization (PSO) optimization algorithms and Voronoi computational geometric algorithm. (3). Selection of base functions, finding optimal penalty factor and distribution of appropriate nodal points to the accuracy of calculation in the meshless local Petrov–Galekrin (MLPG) meshless method.

Using appropriate shape functions and distribution of nodal points in local domains and sub-domains and choosing an approximation or interpolation method has an effective role in the application of meshless methods for the analysis of computational fracture mechanics problems, especially problems with geometric discontinuity and cracks. In this research, computational geometry technique, based on the Voronoi diagram (VD) and Delaunay triangulation and PSO algorithm, are used to distribute nodal points in the sub-domain of analysis (crack line and around it on the crack plane).

By doing this process, the problems caused by too closeness of nodal points in computationally sensitive areas that exist in general methods of nodal point distribution are also solved. Comparing the effect of the number of sentences of basic functions and their order in the definition of shape functions, performing the mono-objective PSO algorithm to find the penalty factor, the coefficient, convergence, arrangement of nodal points during the three stages of VD implementation and the accuracy of the answers found indicates, the efficiency of V-E-MLPG method with Ns = 7 and ß = 0.0037–0.0075 to estimation of 3D-stress intensity factors (3D-SIFs) in computational fracture mechanics.

The present manuscript is a continuation of the studies (Ref. [33]) carried out by the authors, about; feasibility assessment, improvement and solution of challenges, introduction of more capacities and capabilities of the numerical MLPG method have been used. In order to validate the modeling and accuracy of calculations, the results have been compared with the findings of reference article [34] and [35].